Lightweight and fireproof mattress

ABSTRACT

A mattress having a lightweight first foam layer including a top surface and a bottom surface, where the first foam layer is formed from a single piece of molded foam, and where the lightweight first foam layer is formed at least partly from melamine resin.

FIELD

The invention, in embodiments thereof, relates to a mattress and more specifically to an elastic fireproof mattress.

BACKGROUND

The average adult spends about 7-9 hours of sleep a day. Young children spend about 9-14 hours of sleep a day and infants spend about 16 hours a day sleeping. Today, many mattresses are provided in order to provide comfortable and safe sleep. Various attempts have been made to create a mattress which can provide sufficient hardness, elasticity, softness, and comfort. For example, a visco-foam mattress, which offers a high support because of its high density (typically over about 50 Kgs to M3 density) and feels soft and desirable to the user because it typically has an Indentation force-deflection of 15 or under. However, the high cost, bulkiness and heavy weight of the visco-foam remain disadvantages for the end user.

Additionally, many countries have legislated or regulated that mattresses should comply with regulatory standards for being fire-proof. In order to comply with those regulatory standards, many mattresses are formed with fire-redundant materials, which sometimes may be hazardous and/or toxic. With regards to infant mattresses, the addition of hazardous and/or toxic fire redundant is extremely dangerous since infants are more susceptible to the damages caused by unsafe fire redundant. Common fire redundant materials such as bromine, PBDE and the like are known to emit hazardous materials absorbed in the human body which may directly cause respiratory irritation and additional illness.

Therefore, there is a great need for a lightweight mattress which does not comprise hazardous fire redundant materials and provides a desirable material to sleep on and nevertheless, be sufficiently fire proof.

SUMMARY

In one embodiment of the invention a mattress is provided, including a lightweight first foam layer made of melamine resin, the first foam layer having a top surface and a bottom surface, where the first foam layer is formed from a single piece of molded foam and a covering layer configured to cover the first foam layer, where the covering layer is made of a fire-resistant material.

In some cases, the top surface of the first foam layer is shaped as an egg crate pattern. In some cases, the mattress defines an elevated portion adjacent to a rear surface of the first layer, and where the elevated portion forms a pillow. In some cases, the elevated portion is designed with an inclination to form elongated wedge-shaped notches. In some cases, the density of the first foam layer is in a range of 4-10 kg/m3.

In some cases, the mattress lacks fire retardant additives. In some cases, the first foam layer is formed of a polyurethane foam. In some cases, the first foam layer consists of polyurethane foam. In some cases, the first foam layer is formed solely from a melamine resin. In some cases, the melamine resin is a product designated by the trade name “BASOTECT” in the name of BASF, Germany. In further embodiments, the melamine resin is a product designated by the trade name “BASOTECT UF” in the name of BASF, Germany. In some cases, the elastic material is classified as fireproof in accordance with ISO EN 13501-1 as B, s1, d0.

In some cases, the mattress includes a second layer, abutting at least one of the first foam layer surfaces, and where the second layer is formed from a viscoelastic material. In some cases, the second layer abuts the top surface of the material. In some cases, the first foam layer top surface and the first foam layer bottom surface have different widths.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more clearly understood upon reading of the following detailed description of non-limiting exemplary embodiments thereof, with reference to the following drawings, in which:

FIG. 1 shows a lightweight and fireproof mattress comprising a single layer, according to exemplary embodiments of the invention;

FIGS. 2A-2B show a lightweight and fireproof mattress comprising a plurality of layers, according to exemplary embodiments of the invention; and

FIG. 3 shows a lightweight and fireproof mattress comprising an elevated portion, according to exemplary embodiments of the invention.

The following detailed description of embodiments of the invention refers to the accompanying drawings referred to above. Dimensions of components and features shown in the figures are chosen for convenience or clarity of presentation and are not necessarily shown to scale. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts.

DETAILED DESCRIPTION

Illustrative embodiments of the invention are described below. In the interest of clarity, not all features and/or components of an actual implementation are necessarily described.

The invention, in embodiments thereof, provided a fireproof lightweight mattress that lacks any materials that emit gasses to the air, as these gasses may damage the user's health. The term “fireproof” used herein depicts a quality of material in which the material resists damages arising from direct fire or high temperatures derived from indirect fire or heat source. An example for direct fire may be a lit cigarette placed on the mattress. An example of indirect heat source may be a heating element such as a radiator or convector touching the mattress.

FIG. 1 shows a lightweight and fireproof mattress comprising a single layer, according to exemplary embodiments of the invention. FIG. 1 shows a mattress 100 comprising at least a first foam layer 110. In some embodiments, the first foam layer 110 is placed on a support base 120. The first foam layer 110 has a top surface 111, a bottom surface 112, a front side surface 113 a rear side surface 114, a first lateral surface 115 and a second lateral surface 116. In some embodiments, the first foam layer 110 is formed from a single piece of molded lightweight foam. In some embodiments, the top surface 111 of the first foam layer 110 may be designed in a pattern to enhance the comfortability of the mattress. In such cases, the top surface of the first foam layer may be designed, for example, as an egg crate pattern.

The support base 120 is traditionally configured to provide elevation and support for the mattress 100. The support base 120 is typically formed from wood or other material as a solid frame. In some embodiments, the support base 120 may be embedded in the mattress 100 as a second layer, located under the first foam layer 110. In some embodiments, the first foam layer 110 and the support base 120 may be formed of the same material yet with a different density. In other embodiments, the first foam layer 110 may be placed on the ground/floor as a replacement for the support base 120.

In some embodiments, the top surface 111 of the first foam layer 110 may have a different width than the bottom surface 112. In such cases, the first lateral surface 115 and the second lateral surface 116 form elongated wedge-shaped notches. In such cases, the support base 120 may comprise lateral support extensions for supporting the elongated wedge-shaped notches of the first foam layer 110.

In some embodiments, the first foam layer 110 is formed from an elastic material. Elasticity, which is an important concept for the aesthetics and firmness of the mattress 100, is expressed by measurements of resilience and permanent set. In some embodiments, the first foam layer 110 is formed from a material comprising an average tensile strength in the range of 90-110 kPa and/or average elongation at break in the range of 20%-30% in accordance with ISO 1798.

In some embodiments of the invention, the first foam layer 110 is formed from an open-cell material. In further embodiments, the first foam layer 110 is formed from a low-density material. In some embodiments, it is desirable that the first foam layer 110 would be lightweight and have a density in the range of 4-10 kg/m3 which makes the mattress significantly lighter compared to regular mattresses.

In some embodiments, the low density of the mattress derives from an open-cell structure of the material from which the mattress is made. Open-cell structure with low density allows air to flow through the material, making the material breathable. It is desirable to prevent infants to lie on a non-breathable foam surface, to prevent sudden infant death syndrome (SIDS) may be caused by the accumulation of carbon dioxide in bedding. Thus, allowing air to flow through the first foam layer 110, results in fresh air provided to the user sleeping thereon, which is especially relevant for infants.

In some embodiments, the first foam layer 110 is formed from a fire-resistant material. In further embodiments, the fire-resistant material, which the first foam layer 110 is formed of, lacks any additional fire redundant materials or consists of a fire redundant material. In some embodiments, material of the first foam layer 110 comprises fire redundant capabilities in accordance with ISO EN 13501-1 and classified as B, s1 and d0. In further embodiments, the fire-resistant material, which the first foam layer 110 is formed of, comprises high thermal endurance properties. Specifically, in some embodiments, the thermal endurance of the material forming the first layer is measured in accordance with ISO 2578 (and as defined in ISO 3386-1) as resistant to a heat of 220° C. for 1000 hours.

In further embodiments, the fire-resistant material, which the first foam layer 110 is formed of, comprising low thermal conductivity properties. In some cases, the thermal conductivity of the material may be in the range of 0.02-0.05 W/mK. In more specific cases, the thermal conductivity of the material may be in the range of 0.03-0.04 W/mK. In some embodiments, the thermal conductivity is measured in accordance with the DIN EN 12667 regulation.

In some embodiments, the first foam layer 110 is formed from a sound absorbing material. Since many people require a low amount of noise in order to fall asleep, such material would be very beneficial to the formation of a mattress. In some embodiments, the sound absorbing material is formed from an open cell material, comprising a high sound absorption quality. The open cell structure causes the sound waves touching the first foam layer 110 to penetrate the cell structure of the material unhindered in contrast to being reflected from the surface of the first foam material 110 as an echo. Thus, the sound energy is reduced in the cell structure, giving the first foam material 110 an excellent sound absorption capacity. For example, the material may be formed in accordance with regulation ATSM C 426 (U.S.A) as class A. In some embodiments, the thickness of the first foam layer 110 may be determined by the desired level of sound absorption. In some embodiments, the sound absorption for a 50 mm thick layer with a frequency of 2000 Hz is more than 90 percent absorption in accordance with ISO 10534.

In some embodiments, the first foam layer 110 of the mattress 100 may consist of a block of melamine resin, which may be formed as a foam. In further embodiments, the block of melamine foam is formed as an open cell structure. In a non-limiting manner, the block of melamine foam may be the product designated by the trade name “BASOTECT” in the name of BASF, Germany. In further embodiments, the first foam layer 110 of the mattress 100 may consist of the product designated by the trade name “BASOTECT UF” in the name of BASF, Germany. The “BASOTECT UF” is characterized by a very high elasticity and by improved fire properties. In further embodiments, the product designated by the trade name “BASOTECT” is either one of: “BASOTECT UF”, “BASOTECT UF+”, “BASOTECT G” and “BASOTECT G+”.

In some embodiments, the entire mattress 100 may be cut out from a single block of material. In some embodiments, the mattress 100 is not limited to a cubic rectangular shape and may be shaped in any form desirable by a user. For example, using a mold, the mattress 100 can be formed to have a shape of a circle fitting on a circular bed, polygonal shapes and the like. For example, in some embodiments, the mattress 100 is shaped to snugly fit inside an infant crib. In such cases, the mattress 100 may be slightly larger than the dimensions of the crib and inserted into the crib when pressed. Thus, the mattress may snugly fit into a crib, despite small variations in the dimensions of the mattress caused by inconsistent manufacturing processes. In such embodiments, the crib comprising such mattress is safer because there is no gap in which an infant's limb could become lodged in.

The width of the mattress 100 may be in the range of 10-50 centimeters, made from a single sheet of lightweight and fireproof material and covered by a covering sheet which is a thin sheet, for example having width in the range of 1.5-20 millimeters, and made of an open-cell structure. The covering layer may be made of cotton. The length of the mattress 100 may be in the range 80-220 centimeters and the breadth of the mattress 100 may be in the range 30-180 centimeters.

FIGS. 2A-2B show a lightweight and fireproof mattress comprising a plurality of layers, according to exemplary embodiments of the invention. FIG. 2A shows a mattress 200 comprising dual layers. In some embodiments, the mattress 200 comprises a first foam layer 210 and a second foam layer 220. In some embodiments, each layer of the first foam layer 210 and a second foam layer 220 may be assembled of a plurality of sublayers. In some embodiments, the first foam layer 210 is identical to the first foam layer of FIG. 1 as aforementioned. The shape of the first foam layer 210 may vary, and may be rectangular, circular, polygonal or any other shape fitting a user's needs. In some embodiments, the second foam layer 220 abuts at least one surface of the first foam layer 210. In some embodiments, the second foam layer 220 may be formed from a different material from the material of the first foam layer 210 and which can provide a better comfort to the user than the first foam layer 210. In some embodiments, the second foam layer 220 may be formed of viscoelastic material, adapted to distribute the user's weight and to provide a softer layer than the first foam layer 210. In some embodiments, the second foam layer 220 may coat the entire surface of the first foam layer 210.

In some embodiments, the density of the first foam layer 210 is greater than the density of the second foam layer 220 topping the first foam layer 210. In other embodiments, the first foam layer 210 is firm and provides sturdy support to the second foam layer 220, for a uniform texture across the external surface of the mattress 200. The overall thickness of the mattresses depends on the thicknesses of the layers 210, 220 with any additional layer of foam that may optionally be added over the second foam layer 220.

In some embodiments, as shown in FIG. 2B, the mattress 200 comprises three foam layers shaped in accordance with a user's preference. In such cases the mattress 200 comprises a bottom layer 230, a middle layer 232, and a top layer 234. Bottom layer 230 may be formed of regular high-density foam in order to provide stability and support for the mattress 200. In some embodiments, the middle layer 232 is formed of a viscoelastic material and provides a first cushioning layer for the mattress 200. In some cases, the middle layer 232 comprises an egg crate pattern on its top surface. Utilizing an egg crate pattern on the top surface provides a softer feel for the user. The top layer 234 may be formed as a thin sheet of an open cell material having an especially low density to provide a second cushioning interface for the mattress 200. The bottom layer 230, the middle layer 232, and the top layer 234 may be made of melamine foam. In some other embodiments, the bottom layer 230, the middle layer 232, and the top layer 234 may be made of another material that is both fire resistant and of a density lower than 10 kilograms per cubic meter (m3).

FIG. 3 shows a lightweight and fireproof mattress comprising an elevated portion. FIG. 2 shows a mattress 300 comprising a first foam layer 310. The first foam layer has a top surface 311, a bottom surface 312 and a front side surface 313 a rear surface 314, a first lateral surface 315 and a second lateral surface 316. In some embodiments, the first foam layer comprises an elevated foam layer 320 extending from the top surface 311, and adjacent to the rear surface 314 of the first foam layer 310. In some embodiments, the elevated foam layer 320 is shaped a single pillow or two adjacent pillows. The pillows are configured to serve as a head rest for providing additional comfort to a user sleeping thereon. In some embodiments, the first foam layer 310 and the elevated foam layer 320 are formed from a single block of foam. In some embodiments, the elevated foam layer 320 may be inclined to create a wedge shape.

In some embodiments the invention uses a melanin foam in the production of a mattress or another cushioning apparatus. In some exemplary cases, the melanin foam is sliced from a sheet of material according to a predefined shape and covered by cotton or another open-cell structure. In some embodiments the invention uses melanin foam in the fabrication of a mattress, such that the mattress allows air flow from a bottom surface of the mattress to the top surface of the mattress. In some embodiments the invention provides a mattress made of fire resistant material that does not emit gasses, such as bromine. The fire resistance means that the mattress remains solid and firm even when caught by fire and does not change its shape and/or chemical characteristics.

It should be understood that the above description is merely exemplary and that there are various embodiments of the invention that may be devised, mutatis mutandis, and that the features described in the above-described embodiments, and those not described herein, may be used separately or in any suitable combination; and the invention can be devised in accordance with embodiments not necessarily described above. 

What is claimed is:
 1. A mattress, comprising: a lightweight first foam layer comprising a top surface and a bottom surface, wherein the first foam layer is formed from a single piece of molded foam, wherein said lightweight first foam layer is formed at least partly from melamine resin.
 2. The mattress of claim 1, wherein the top surface of the first foam layer is shaped as an egg crate pattern.
 3. The mattress of claim 1, wherein the mattress defines an elevated portion on the top surface and adjacent to a rear surface of the first foam layer, and wherein the elevated portion forms a pillow.
 4. The mattress of claim 3, wherein the elevated portion is designed with an inclination to form elongated wedge-shaped notches.
 5. The mattress of claim 1, wherein the density of the first foam layer is in a range of 4-10 kg/m³.
 6. The mattress of claim 1, wherein the mattress lacks fire retardant additives.
 7. The mattress of claim 1, wherein the first foam layer is partly formed of a polyurethane foam.
 8. The mattress of claim 1, wherein the first foam layer is formed solely from/composed of a melamine resin.
 9. The mattress of claim 8, wherein the melamine resin is a product designated by the trade name “BASOTECT” in the name of BASF, Germany.
 10. The mattress of claim 9, wherein the product designated by the trade name “BASOTECT UF” is either one of: “BASOTECT UF”, “BASOTECT UF+”, “BASOTECT G” and “BASOTECT G+”.
 11. The mattress of claim 1, wherein the first foam layer is formed from a material that is classified as fireproof in accordance with ISO EN 13501-1 in categories B, s1 and d0.
 12. The mattress of claim 1, wherein the first foam layer is formed from a material that is classified as fireproof in accordance with ISO EN 13501-1 in categories B, s1 and d0.
 13. The mattress of claim 1, wherein the first foam layer comprises low thermal conductivity properties, wherein low the thermal conductivity is measured in the range of 0.02-0.05 W/mK.
 14. The mattress of claim 1, wherein the first foam layer is formed from a material comprising a tensile strength in the range of 90-110 kPa and average elongation at break in the range of 20%-30% in accordance with ISO
 1798. 15. The mattress of claim 1, wherein the first foam layer top surface and the first foam layer bottom surface have different widths.
 16. The mattress of claim 1, wherein the first foam layer is formed with an open cell structure.
 17. The mattress of claim 1, further comprising a covering layer configured to cover the first foam layer, said covering layer is made of a fire-resistant material.
 18. The mattress of claim 1, wherein the mattress comprising a second layer, abutting at least one of the first foam layer surfaces, and wherein the second layer is formed from a viscoelastic material.
 19. The mattress of claim 18, wherein the second layer abutting the top surface of the material.
 20. The mattress of claim 1, wherein the first foam layer is formed from a material providing more than 25 N under an indentation hardness test.
 21. The mattress of claim 1, wherein the sound absorption for a 50 mm thick first layer with a frequency of 2000 Hz is more than 90 percent absorption in accordance with ISO
 10534. 